PRODUCT SUPPORT PROGRAM FOR REPLACING THE PLATE FOR THE MUFFLER GROUP ON CERTAIN 385C, 385CL, 385C FS, AND 385CL MH EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE PLATE FOR THE MUFFLER GROUP ON CERTAIN 385C, 385CL, 385C FS, AND 385CL MH EXCAVATORS [REBE3281]

AIR INLET AND EXHAUST SYSTEM

MUFFLER GP

PRODUCT SUPPORT PROGRAM FOR REPLACING THE PLATE FOR THE MUFFLER GROUP ON CERTAIN 385C, 385CL, 385C FS, AND 385CL MH EXCAVATORS

REBE3281-00

Show/hide table

27May2008

U-276

A-225

D-223

O-245

Show/hide table

*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE PLATE FOR THE MUFFLER GROUP ON CERTAIN 385C, 385CL, 385C FS, AND 385CL MH EXCAVATORS
1062		PS42706

Show/hide table

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42706" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your AVSpare product analyst.

Show/hide table

TERMINATION DATE

31May2010

PROBLEM

Show/hide table

The existing plate for the muffler group can fail on certain 385C, 385CL, 385C FS and 385CL MH Excavators due to the vibration by resonance. If the existing 279-7788 Plate fails, it can cause the engine cover seal to deteriorate and leak.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
385C OEM	MSF00101-00102, 104, 106-109
CIPI	0EM01404, 1539, 1839, 1887, 1891

Show/hide table

*****Group 2*****
385C	JCM00175-00178 KBC00201-00240 KKK00123-00194
385C FS	EAM00264-00285 MMA00245-00258 T2F00181-00188
385C L	EDA00189-00456 KGB00275-00404 SBE00168-00290 T2E00291-00341
385C L MH	WAW00211-00220

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
1	5I8748	SPACER
8	5P4115	WASHER-HARD
1	6V7357	BOLT
7	8T4138	BOLT
3	8T4908	BOLT-HEX HEAD
1	8X1386	SPACER
1	3109504	PLATE
1	3109513	BRACKET AS
1	3109760	PLATE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	5I8748	SPACER
8	5P4115	WASHER-HARD
1	6V7357	BOLT
7	8T4138	BOLT
3	8T4908	BOLT-HEX HEAD
1	8X1386	SPACER
1	3109504	PLATE
1	3109513	BRACKET AS
1	3109760	PLATE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

Show/hide table

Refer to the attached Rework Procedure to replace the plate assembly, the plate and the bracket.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 25-48 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 1

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 25-48 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 2

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Note: Use reusable parts for installing.

Procedure for removing the muffler plate and support plate

1) Remove the 7X-0289 Bolts (3/8-16), washers, 217-5449 Spacers, and the muffler cover. Refer to Image 1.1.1.

Image1.1.1

2) Remove the 7X-0289 Bolt (3/8-16), 8T-4896 Washer, 1B-3057 Clip, and boss. Refer to Image 1.2.1.

Image1.2.1

3) Remove the 4L-9337 Bolt (3/8-16), 8T-4896 Washer, and spacer. Refer to Image 1.3.1.

Image1.3.1

4) Remove the bolt, washer, muffler plate, and support plate. Refer to Image 1.4.1.

Image1.4.1

Procedure for removing the muffler

1) Remove the 233-1188 U-Bolt, 8T-4244 Nut, and 289-2492 Clamp. Remove the muffler. Refer to Image 1.5.1.

Image1.5.1

2) Remove the 8T-4956 Bolts (M12x1.75) and 8T-4223 Washer. Remove the 8T-2501 Bolts (3/8-16) and 205-6716 Spacer. Remove the muffler bracket. Refer to Image 1.6.1.

Image1.6.1

Procedure for installing the muffler

1) Install the 310-9513 Muffler Bracket to the engine block with 8T-4956 Bolts and 8T-4223 Washers. Tighten the bolts to a torque of 100 +/- 20Nm. Install the 8T-2501 Bolts and 205-6716 Spacers. Tighten the bolts to a torque of 47 +/- 9Nm. Refer to Image 1.7.1.

Image1.7.1

2) Install the muffler with the 233-1188 U-Bolts and 8T-4244 Nuts. Tighten the u-bolts to a torque of 60 +/- 12Nm. Install the 289-2492 Clamp and tighten to a torque of 68 +/- 12Nm. Refer to Image 1.8.1.

Image1.8.1

Procedure for installing support plate and muffler plate

1) Install the 310-9760 Support Plate and 310-9504 Muffler Plate with 8T-4138 Bolts (M6x1) and 5P-4115 Washers. Tighten the bolts to a torque of 12 +/- 3Nm. Refer to Image 1.9.1.

Image1.9.1

2) Install the support plate and the muffler plate to the engine block with 8X-1386 Spacers, 4L-9337 Bolts, and 8T-4896 Washers. Tighten to a torque of 50 +/- 10Nm. Install 5I-8748 Spacer, 7X-0289 Bolt (3/8-16), 8T-4896 Washer, and 1B-3057 Clip. Tighten to a torque of 50 +/- 10Nm.

Then install the muffler plate to the bracket with 6V-7357 Bolt(M6x1) and 5P-4115 Washer. Tighten the bolt to a torque of 12 +/- 3Nm. Refer to Image 1.10.1.

Install SPACER. Tighten BOLT(7X-0289 3/8-16), WASHER(8T-4896) and CLIP(1B-3057)
all together to the support plate.

Image1.10.1

3) Install the muffler cover to the support plate with 8T-4908 Bolts and 5P-4116 washers. Tighten the bolts to a torque of 30 +/- 7Nm.

Then install the muffler cover to the engine block with 7X-0289 Bolts (3/8-16) and 217-5449 Spacers. Tighten the bolts to a torque of 50 +/- 10Nm. Refer to Image 1.11.1.